1996 TOYOTA RAV4 Oil pump

AT3327
Z11664
B A
B
B A
B A
A A C
AT8586
AT8584
Q06418
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
AX−7
1996 RAV4 (RM447U)
11. INSTALL VALVE BODY
(a) Install the valve body.
(b) Connect the manual valve connecting rod.
(c) Install the 17 bolts and wire retainer.
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 30 mm (1.18 in.)
Bolt C: 55 mm (2.17 in.)
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
(d) Connect the throttle cable.
12. CONNECT 3 SOLENOID CONNECTORS
13. INSTALL MANUAL DETENT SPRING
Install the manual detent spring with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
14. INSTALL OIL PIPE CLAMP AND OIL PIPES
(a) Install the 5 pipes with a large screwdriver.
(b) Install the oil pump clamp with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

CO0BK−01
S01348
CO−10
− COOLINGTHERMOSTAT
1996 RAV4 (RM447U)
REMOVAL
HINT:
Removal of the thermostat would have an adverse effect, caus-
ing a lowering of cooling efficiency. Do not remove the thermo-
stat, even if the engine tends to overheat.
1. DRAIN ENGINE COOLANT
2. REMOVE OIL FILTER (See page LU−2)
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts, and disconnect the water inlet from
the water pump cover.
(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.

CO0BM−02
P13611
Protrusion
Jiggle
Valve5° 5° CO−12
− COOLINGTHERMOSTAT
1996 RAV4 (RM447U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion
of the water inlet, and insert the thermostat in the water
inlet.
HINT:
The jiggle valve may be set within 5° of either side of the pre-
scribed position.
2. INSTALL WATER INLET AND THERMOSTAT
Install the water inlet and thermostat with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
3. INSTALL OIL FILTER (See page LU−2)
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS
6. CHECK ENGINE OIL LEVEL

S02410
EFI
MAIN No.1
IG Switch AM2
MAIN
FL
BatteryPark/Neutral
Position Switch
(Clutch Start
Switch)EFI Main
RelayCircuit Opening
Relay
Fuel Pump
ECM
FC
Tr
STA
NE (STA Signal)
(NE Signal) Starter IGN
ST Relay DI−11 6
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
Fuel Pump Control Circuit
CIRCUIT DESCRIPTION
In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to
the starter relay coil and also current flows to terminal STA of ECM (STA signal).
When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit
opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates.
While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the
fuel pump also keeps operating.
DI407−02

DI−136
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
9. HYDRAULIC TEST
Measure the line pressure.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
The line pressure test should always carried out in pairs. One technician should observe the
conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe.
(1) Warm up the ATF.
(2) Remove the teat plug on the transaxle case left side and connect SST (See page AX−14. for the
location to connect SST).
SST SST 09992−00094 (09992−00230, 09992−00270)
(3) Chock the 4 wheels.
(4) Fully apply the parking brake.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressed firmly on the brake pedal and shift into the D position.
(7) Measure the line pressure when the engine is idling.
(8) Fully depress the accelerator pedal. Quickly read the highest line pressure when engine speed
reaches stall speed.
NOTICE:
Release the accelerator pedal and stop test if the wheels being to rotate before the engine speed
reaches specified stall speed.
(9) In the same way, do the teat in R position.
Specified line pressure:
ConditionD position kPa (kgf/cm2, psi)R position kPa (kgf/cm2, psi)
Idling353 − 422 (3.6 − 4.3, 51 − 61)598 − 804 (6.1 − 8.2, 87 − 117)
Stall824 − 971 (8.4 − 9.9, 119 − 141)1,530 − 1,780 (15.6 − 18.1, 222 − 257)
If the measured pressures are not up to specified values, recheck the throttle cable adjustment and do a
retest.
Evaluation:
ProblemPossible cause
If the measured value in all positions are higher.
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured values in all positions are lower.
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
U/D direct clutch defective
If pressure is low in the D position only.D position circuit fluid leakage
Forward clutch defective
If pressure is low in the R position only.
R position circuit fluid leakage
Direct clutch defective
1st and reverse brake defective

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−143
1996 RAV4 (RM447U) Poor acceleration
1. Primary regulator valve
2. Off−vehicle matrix chart
−
No lock−up1. Look−up relay valve
2. Off−vehicle matrix chart
−
Chapter 3: Off−Vehicle Repair
(: A241E, A244E, A245E, A246E Automatic Transaxle Repair Manual Pub. No. RM390U)
SymptomSuspect AreaSee page
Does not move in any forward position1. Forward clutch (C1)
Does not move in reverse position
1. Direct clutch (C2)
2. 1st and reverse brake (B
3)
3. U/D brake (B
4)



Does not move in any position
1. Torque converter clutch
2. Oil pump
3. U/D one−way clutch (F
3)
4. Front planetary gear
5. Rear planetary gear
6. On−vehicle matrix chart
AX−20




−
No up−shift (1st → 2nd)
1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)
3. On−vehicle matrix chart


−
No up−shift (2nd → 3rd)1. Direct clutch (C2)
2. On−vehicle matrix chart
−
No up−shift (3rd → O/D)1. U/D brake (C3)
2. On−vehicle matrix chart
−
No down−shift (O/D → 3rd)
1. U/D brake (B4)
2. U/D one−way clutch (F
3)
3. On−vehicle matrix chart


−
No down−shift (3rd → 2nd)1. No. 1 one−way clutch (F1)
2. On−vehicle matrix chart
−
No down−shift (2nd → 1st)1. No. 2 one−way clutch (F2)
2. On−vehicle matrix chart
−
Harsh engagement (N → R)
1. Direct clutch (C2)
2. 1st and reverse brake (B
3)
3. On−vehicle matrix chart


−
Harsh engagement (N → D)1. Forward clutch (C1)
2. On−vehicle matrix chart
−
Harsh engagement (N → L)
1. Forward clutch (C1)
2. 1st and reverse brake (B
3)
3. On−vehicle matrix chart


−
Harsh engagement (1st → 2nd (D position))
1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)
3. On−vehicle matrix chart


−
Harsh engagement (1st → 2nd (2 position))
1. 2nd coast brake (B1)
2. 2nd brake (B
2)
3. No. 1 one−way clutch (F
1)
4. On−vehicle matrix chart



−
Harsh engagement (1st → 2nd → 3rd → O/D)1. On−vehicle matrix chart−
Harsh engagement (2nd → 3rd)1. Direct clutch (C2)
2. On−vehicle matrix chart
−
Harsh engagement (3rd → O/D)1. U/D clutch (C3)
2. On−vehicle matrix chart
−

DI−144
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U) Harsh engagement (O/D → 3rd)
1. U/D brake (B4)
2. On−vehicle matrix chart
−
Harsh engagement (3rd → 2nd)1. Direct clutch (C2)
2. On−vehicle matrix chart
−
Harsh engagement (Lock−up)1. Torque converter clutchAX−20
Slip (Forward & reverse)
1. Torque converter clutch
2. Oil pump
3. On−vehicle matrix chartAX−20

−
Slip (R position)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Slip (1st)
1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)
3. U/D one−way clutch (F
3)



Slip (2nd)
1. Forward clutch (C1)
2. 2nd brake (B
2)
3. No. 1 one−way clutch (F
1)
4. U/D one−way clutch (F
3)

Slip (3rd)
1. Forward clutch (C1)
2. Direct clutch (C
2)
3. U/D one−way clutch (F
3)



Slip (O/D)
1. Forward clutch (C1)
2. Direct clutch (C
2)
3. U/D clutch (C
3)



No engine braking (1st (L position))1. 1st and reverse brake (B3)
2. On−vehicle matrix chart
−
No engine braking (2nd (2 position))1. 2nd coast brake (B1)
2. On−vehicle matrix chart
−
No kick−down1. On−vehicle matrix chart−
Poor acceleration
1. Torque converter clutch
2. Forward clutch (C
1)
3. On−vehicle matrix chart
AX−20

−
No lock−up1. Torque converter clutch
2. On−vehicle matrix chartAX−20
−
Engine stalls when staring off or stopping1. Torque converter clutchAX−20

D02249
1
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−185
1996 RAV4 (RM447U)
CAUTION:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
The line pressure test should always be carried out in parts. One should observe the conditions
of wheels or wheel stopper outside the vehicle while the other is performing the test.
(b) Measure the line pressure.
(1) Fully apply the parking brake and chock the 4 wheels.
(2) Start the engine and check idling speed.
(3) Step down strongly on the brake pedal with your left foot and shift into the D position.
(4) Measure the line pressure when the engine is idling speed.
(5) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine
speed reaches stall speed.
(6) Only when the shift solenoid valve ST is opened:
Apply battery positive voltage between terminal of the solenoid connector and body ground.
(7) In the same way, perform the test in the R position.
Automatic Transaxle Idling kPa (kgf/cm2, psi) Stall kPa (kgf/cm2, psi)
* D position (Shift solenoid valve ST open)530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
D position (Shift solenoid valve ST close)363 − 442 (3.7 − 4.3, 53 − 61)736 − 863 (7.5 − 8.8, 106 − 125)
R position530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
*: When battery voltage is supplied to terminal 4 of the solenoid connector and body ground, the shift sole-
noid valve ST valve is open.
If the measured pressures are not with in the specification, recheck the throttle cable adjustment and perform
a retest.
(8) Clear the DTC’s after the test.
Evaluation:
ProblemPossible cause
If the measured values at all positions are higher than speci-
fiedThrottle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured value in all positions are lower than speci-
fied
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective